Interpolymerization product of a polycrotyl ester and an unsaturated alkyd resin



Patented Jan. 19, 1943 INTEBI'OLYMERIZATION POLYCROTYL ESTER PRODUCT OF A AND AN UNSAT- UBATED ALKYD RESIN Gaetano F. DAlelio, Pittsfield, Mass.,- assignor to General Electric Company, a corporation of New York No Drawing. Application October 31, 1939, Serial No. 302,172

17 Claims.

This invention relates to the production of new materials having valuable and characteristic properties that make them especially suitable for use in industry, for example in molding, laminating, casting, coating and adhesive applications, and for other purposes. The invention is concerned more particularly with compositions of matter comprising an interpolymer (copolymer) or interpolymers of at least one modified or unmodified polyhydric alcohol ester of an alpha unsaturated alpha beta polycarboxylic acid (hereafter for brevity designated generally as an "unsaturated alkyd resin) and at least one polycrotyl (dicrotyl, tricrotyl, etc.) ester of a non-ethylenic polycarboxylic acid such, for instance, as saturated aliphatic (including saturated cycloaliphatic) and aromatic polycarboxylic acids. Specifically the invention relates to (A) polymerizable compositions consisting of (1) an unsaturated alkyd resin, (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids, and (3) a catalyst for accelerating the copolymerization of the copolymerizable-materials of (1) and (2); and to (B) polymerized compositions obtained by polymerizing the polymerizable com positions of (A). Illustrative of the new products of the invention are synthetic, polymerized materials consisting of an interpolymer of an unsaturated alkyd resin and dicrotyl succinate, adipate or phthalate.

The crotyl esters of non-ethylenic polycarboxylic acids used in carrying the present invention into effect may be considered as being gamma-methyl allyl esters having the graphic formula where n has a numerical value of at least 2 and Y is a radical ofa non-ethylenic polycarboxylic acid (or anhydride thereof if available) containing at least two esterifiable carboxy groups. From the above formula it will be seen that polyesters, the alcohol radicals of which contain the grouping, CH3CH=CHCH:, are embraced by this invention. The term polycrotyl ester of a non-ethylenic polycarboxylic acid, as used generally herein, is intended to include within its meaning esterification products of a non-ethylenic polycarboxylic acid, or an anhydride thereof if available, with the above-described alcohols. Illustrative of the non-ethylenic polycarboxylic acids that may be employed in preparing these polycrotyl esters are the saturated aliphatic polycarboxvlic acids such as oxalic, malonic, succinic, adipic, glutaric, pimelic, sebacic, azelaic, suberic, tricarballylic, etc. the saturated cycloaliphatic polycarboxylic acids, e. g., the cyclopropane dicarboxylic acids, the cyclohexane dicarboxylic acids, the alkyl cycloalkane polycarboxylic acids, etc., the aromatic polycarboxylic acids, e. g., phthalic, benzoyl phthalic, terephthalic, benzophenone dicarboxylic, etc., the hydroxy saturated polycarboxylic acids, e. g., citric, tartaric, etc., and similar sub stances. I

The polycrotyl esters used in carrying the present invention into effect are, in themselves, relatively inactive polymerizing bodies. If polymerization does occur, the polymers usually are of a low molecular weight, fluid nature and are of limited commercial value. 0n the other hand, the unsaturated alkyl resins alone are unsuited, even in the presence of polymerization catalysts such as peroxides, for the preparation of practically useful massive bodies. With or without peroxides or other polymerization catalysts, however, they may be applied in film form and, under the influence of heat or light, or heat and light,

may be converted in a reasonable time to a cured film. But if effort be made to prepare commercially useful massive bodies from the unsaturated alkyds alone, heat treatment even for 24 hours in the presence of a polymerization catalyst such as super-peroxides usually gives unsuitable materials; that is, they generally lack the properties required for the usual service applications. For example, the cast or molded articles often are soft, rubbery masses (even after heat treatment for 24 hours at elevated temperatures) or, if hard bodies, frequently are filled with bubbles or show cracks, or both, when cured.

It was therefore quite surprising and unexpected to find that by copolymerizing a polycrotyl ester of a non-ethylenic polycarboxylic acid with an unsaturated alkyd resin, interpolymers were obtained having properties quite different from the properties of the individual components when polymerized under the same conditions. The properties of the interpolymers range, for .example, from hard, tough, insoluble and infusible bodies both in film form and when cast or molded in large size to softer, flexible bodies or rubbery masses. In general, the properties of these new products are such as to render them suitable for a wide variety of technical applications.

Compositions produced in accordance with this invention also are particularly well adapted for use as "solventless varnishes," for instance as coating compositions and binders in the production of laminated sheets and tapes for use' in insulating electrical devices, as well as for other applications.

Another practical advantage accruing from my invention is that the polycrotyl esters of non-ethylenic polycarboxylic acids are good dispersion mediums for polymerization catalysts such as super-peroxides, which catalysts are dissolved or dispersed in the unsaturated alkyd resins alone only with great difficulty.

In carrying the present invention into effect a polymerizable esterification product of a polyhvdric alcohol and an alpha unsaturated alpha beta polycarboxylic acid is first prepared in accordance with technique now well known to those skilled in the alkyd-resin art. Any polyhydric alcohol containing at least two esterifiable aliphatic hydroxyl groups, or mixtures 01' such alcohols, may be used in preparing the unsaturated alkyd resin. Examples of such polyhydric alcohols are ethylene glycol, di-, tri-, and tetraethylene glycols, propylene glycol, trimethylene glycol, thiodiglycol, glycerine, pentaerythritol. etc. Any alpha unsaturated alpha beta polycarboxylic acid, or mixtures of such acids, may be reacted with the polyhydric alcohol or alcohols to form the unsaturated alkyd resin. Examples of such polycarboxylic acids are maleic, monohalomaleic, fumaric, monohalofumaric, citraconicjmesaconic. acetylene dicarboxylic, aconitic, itaconlc and its homologues as, for instance, alpha methyl itaconic acid, alpha ethyl itaconic acid, alpha alpha dimethyl itaconic acid, etc. If available, anhydrides of these polycarboxylic acids may be employed.

The terms polycarboxylic acid and dicarboxylic acid," as used generally herein and in the appended claims with reference to non-ethylenicAO polycarboxylic acids and alpha unsaturated alpha beta polycarboxylic acids, are intended to include within their meaning the anhydrides of such acids.

In some cases, instead of using an unmodified unsaturated alkyd resin I may use a polymerizable unsaturated alkyd resin which has been internally modified by replacing a part, say up to about 75 mol per cent, of the unsaturated polycarboxylic acid with a non-ethylenic polycarboxylic acid, for example a saturated aliphatic polycarboxylic acid such as succinic, adipic, glutaric, pimelic, sebacic, azelaic, suberic, tricarballylic, etc., an aromatic polycarboxylic acid, e. g., phthalic, benzoyl phthalic, terephthalic, etc or with anhydrides of such acids if available.

The term unsaturated alkyd resin" as used generally herein and in the appended claims is intended to include within its meaning bot-h unmodified esterification products of a polyhydric alcohol with an alpha unsaturated alpha beta polycarboxylic acid and polymerizable esterification products of the said components which have been modified, for example, as above briefly described.

To achieve copolymerization of the unsaturated alkyd resin with the polycrotyl ester, a solution of the said resin in the said ester first preferably is effected. The polycrotyl ester also advantageously may act as the carrier for a small amount of a polymerization catalyst. Examples of polymerization catalysts that may be used are ozone, ozonides, inorganic super-oxides such as barium peroxide, sodium peroxide, etc., aliphatic acyl peroxides, e. g., acetyl peroxide, lauryl peroxide.

stearyl peroxide, etc., peroxides of the aromatic acid series, e. g.,-benzoyl peroxide, various percompounds such as perborates, persulfates, perchlorates, etc., aluminum salt such as the halides, organic and inorganic acids such as methacrylic acid, hydrofluoric acid, etc., metal compounds oi. the unsaturated acids as, for instance, cobalt and manganese resinates, linoleates, maleates, etc. Benzoyl peroxide is the preferred catalyst. Any suitable amount of catalyst may be used, but in general the catalyst concentration will be within the range of 0.1 to 2.0 per cent by weight 01' the whole.

When rapidity of interpolymerization between the polycrotylester and the unsaturated alkyd resin is of secondary importance, copolymerization between these components may be effected merely under the influence of heat, light, or heat and light and in the absence of an accelerator of polymerization. The rate of copolymerization and the properties of the final product vary with the time, temperature and, it a catalyst is used, also with the catalyst concentration. Copolymerization may be effected at from roomtemperature (20 to 30 C.) to temperatures above C., for example about C., but ordinarily I use temperatures within the range of 60 to 120 C. in causing the mixed components to interpolymerize.

In order that those skilled in the art better may understand how the present invention may be carried into eflect, the following example is gi en by way of illustration. All parts are by weight.

I Parts Dlethylene glycol maleate 90 Dicrotyl succinate 20 Benzoyl peroxide 1 1 Nora-The diethylene glycol maleate was prepared by esteritlylng 147 parts maleic anhydride with parts diethy ene glycol. The mixed reactants were heated in a nitrogen atmosphere, the temperature being brought to C. in one hour and held at that temperature for about 3 to 5 hours.

The benzoyl peroxide was dissolved in the dicrotyl succinate and the resulting solution was mixed with the dietbylene glycol maleate. The mixture was then subjected to heat, specifically a temperature of about 85' to 90 C. In about 20 minutes the solution was converted to an insoluble, infusible composition. When a, small sample of the mixed components was heated on a 130 C. hot plate, it hardened in less than 60 seconds.

Fillers such as alpha cellulose, shredded cellulose derivatives, wood flour, asbestos, paper, cloth, etc., may be impregnated with the mixed unpolymerized or partially polymerized components and the mass hardened under heat or under heat and pressure to yield molded articles of good appearance and physical characteristics.

It will be understood, of course, that my invention is not limited to interpolymerization products of the specific esters, namely, diethylene glycol maleate and dicrotyl succinate, given in the above illustrative example and that instead of using dicrotyl succinate I may use a polycrotyl ester of any other non-ethylenic polycarboxylic acid, for example dicrotyl oxalate, malonate, adipate, glutarate, sebacate, azelate, pimelate, tartrate, phthalate, etc., tricrotyl citrate, tri-carballylate, etc. Likewise, instead of using diethylene glycol maleate, I may use any other polymerizable unsaturated alkyd resin, for example the esterification products of Diethylene glycol (106 parts) and itaconic acid (130 parts) Glycerine (18.4 parts) and itaconic acid (39 parts) Thiodiglycol (24 parts) and itaconic acid (26 parts) Ethylene glycol (62.05 parts), itaconic acid (32.51

parts) and phthalic anhydride (111.03 parts) Glycerine (20parts) itaconic acid (29 parts) and phthalic anhydride (11 parts) Diethylene glycol (20 parts), itaconic acid (18.2

parts) and succinic acid (7.08 parts) Diethylene g ycol (306 parts), maleic anhydride (17.6 parts) and itaconic acid (15.6 parts) Ethylene glycol (20 parts), maleic anhydride (29.4 parts) and succinic acid (3.3 parts) Glycerine (18.4 parts) and maleic anhydride (29.4 parts) Diethylene glycol (30.3 parts), maleic anhydride (13.2 parts) and phthalic anhydride (21.7 parts) Glycerine (25.76 parts), maleic anhydride (13.72 parts), and phthalic anhydride (20.72 parts) Ethylene glycol (18 parts) and maleic anhydride (27.4 parts) Ethylene glycol (23 parts) and itaconic acid (52 p rts).

Etc.

carboxylic acid with a single unsaturated alkyd resin. I may copolymerize a plurality of such esters either with a single unsaturated alkyd resin or with a plurality of such resins. In this way it is possible to obtain a composition comprising a mixture of interpolymers best adapted to meet a particular service application.

Although in the foregoing example I have shown an interpolymerization product of a minor proportion (approximately 18 per cent by weight of the mixed components) of a polycrotyl ester with a major proportion of an unsaturated alkyd resin, it will be understood of course that the invention is not limited to these particular proportions of components. Mainly for economic reasons I prefer that the polycrotyl ester does not exceed substantially 50 per cent by weight of the mixed materials, but the use of higher amounts is not precluded. as for"'example up to, say, 60 or 65 per cent by weight of the whole. The incorporation of a small amount, e. g., 1 or 2 per cent, of a polycrotyl ester of a non-ethylenic polycarboxylic acid into a polymerizable unsaturated alkyd resin has a beneficial efiect upon such alkyd resins, yielding products of improved properties as compared with unsaturated alkyd resins which have been polymerized in the absence of such polycrotyl esters. However, somewhat better results are obtained when the said ester constitutes at least 5 per cent of the mixed starting components. In general, the proportions will be varied depending upon the particular properties desired in the interpolymer.

The interpolymerization products of this invention have a wide range of properties. Depending, for example, upon the particular polycrotyl ester and the particular unsaturated alkyd resin employed, the particular proportions thereof, the particular conditions of polymerization and the extent of the interpolymerization, they vary from soft, flexible, soluble bodies to hard, rigid 'masses of varying resistance to solvents. In intermediate stages of copolymerization some form fluid compositions of varying intrinsic viscosities and may be so used. For coating or impregnating applications where the presence of a small amount of solvent in the cured composition is not objectionable, the mixed starting components may be diluted with volatile or nonvolatile solvents to viscosities best adapted to meet the particular service application, and then may be copolymerized after application of the solution to the particular article to be coated or impregnated. By suitable selection of the starting materials and the conditions of interpolymerization, interpolymers can be obtained in an insoluble, infusible state practically resistant to the destructive effect of other chemical bodies such as acids, bases, solvents, and the like.

These new interpolymers may be used alone or with fillers or other modifying agents, for example in casting, molding and laminating applications, as adhesives, impregnants and surf ace-coating materials. They may be used as impregnants for many porous bodies, such as cork, pottery, felts, or fabricated bodies with interstices, e. g., the windings of electrical coils, netted fiber, interwoven fibrous materials, etc. They also may be used for protectively coating impervious articles such as metals, or for coating or coating and impregnating articles such as paper, wood, cloth, glass fibers, concrete, synthetic boards, etc. They also may be employed in the production of wire enamels and winding tapes The mixed components or partial interpolymers thereof, with or without modifying agents, may be cast and molded under heat or under heat and pressure. They also may be molded by injection, extrusion or compression molding t 2h nique whereby they are heatand pressure-h rdened to yield molded articles of manufacture for various industrial, household and novelty uses.

What I claim as new and desire to secure by Letters Patent of the United States is:

l. A polymerizable composition consisting of (i) an unsaturated alkyd resin, (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids. and (3) a catalyst for accelerating the copolymerization of the copolymerizable materials of (l) and (2 2. The polymerized composition of claim 1.

3. A synthetic, polymerized composition which is the product of polymerization of a mixture of copolymerizable materials consisting of (1) an unsaturated alkyl resin and (2) a polycrotyl ester of a saturated aliphatic polycarboxylic acid.

4. A synthetic, polymerized composition which is the product of polymerization of a mixture of copolymerizable materials consisting of (1) an unsaturated alkyd resin and (2) a polycrotyl ester of an aromatic polycarboxylic acid.

5. As a new product, a synthetic, polymerized material consisting of an interpolymer of dicrotyl succinate and an unsaturated alkyd resin.

6. As a new product, a synthetic, polymerized material consisting of an interpolymer of dicrotyl adipate and an unsaturated allwd resin.

7. As a new product, a synthetic, polymerized material consisting of an interpolymer of dicrotyl phthalate and an unsaturated alkyd resin.

8. A synthetic, polymerized composition which is the product of polymerization of a mixture of copolymerizable materials consisting of (1) an unsaturated alkyd resin obtained by esterifying a dihydric alcohol with an alpha unsaturated alpha beta dicarboxylic acid and (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids.

9. A synthetic, polymerized composition which is the product of polymarization of a mixture of copolymerizable materials consisting of (l) a polymerizable esterification product of a polyhydric alcohol, an alpha unsaturated alpha beta polycarboxylic acid and a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids, and (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids.

10. A synthetic, polymerized composition consisting of an interpolymer of (l) a maleic ester of a polyhydric alcohol and (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids.

11. A synthetic, polymerized composition consisting of an interpolymer of (1) an itaconic ester of a polyhydric alcohol and (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids.

12. A synthetic, polymerized composition consisting of an interpolymer of (1) a fumaric ester of a polyhydric alcohol and (2) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids.

13. The method of producing new synthetic compositions which comprises (1) forming a polymerizable composition consisting of (a) an unsaturated alkyd resin, (b) a polycrotyl ester selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids, and (c) a catalyst for accelerating the copolymerization of the copolymerizable material of (a) and (b), and (2) polymerizing the said polymerizable composition to form an interpolymer of the said unsaturated alkyd resin and polycrotyl ester.

14. A synthetic, polymerized composition obtained by polymerization of a mixture of copolymerizable materials, by weight, from 1 to 65 per cent of (1) a polycrotyl ester of a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids. and aromatic polycarboxylic acids, and (2) from 35 to 99 per cent of an unsaturated alkyd resin.

15. A synthetic, polymerized composition consisting of an interpolymer of dicrotyl phthalate and a maleic ester of a polyhydric alcohol.

16. A synthetic, polymerized composition consisting of an interpolymer of dicrotyl succinate and a fumaric ester of a polyhydric alcohol,

17. A synthetic, polymerized composition consisting of an interpolymer of dicrotyl adipate and an itaconic ester of a polyhydric alcohol.

GAETANO F. I D AIEHO.

CERTIFICATE OF CORRECTION. Patent No. 2,508,1;9l+. January 19, 19h

GAETANO F; D ALELIO.

It is hereby certified that error appearsin the printed specification of the above numbered patent requiring correction as follows: Page 1, second column, line 5,after"'etc. insertacomma; line 19, for "alkyl" read .-alkyd page 2, second column, line 70, for "azelate" read -aze1aate--; page 5, second column, line 57, claim 5, for "alkyl" read alkyd--; page 14., second column, line 12, claim 15, for material read -materials--; line 18, claim 111., after "materials" and before the comma insert --consist ing of-; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in th Patent Office.

Signed and sealed this 2nd day of march, A. D. 19%.

Henry Van Arsdale) (Seal) Acting Commissioner of Patents. 

